Author Topic: axial generator with lamination core (Read 114367 times)

mbouwer · « **Reply #231 on:** May 12, 2019, 05:42:52 AM »

It's always great to look at the creations of others I also find.
With regard to the development of small DIY Mills; how can we obtain more cooperation?

Frank S · « **Reply #232 on:** September 19, 2019, 10:20:05 PM »

Haven't seen an update to your design in a while and was just wondering how it is going.

mbouwer · « **Reply #233 on:** May 10, 2020, 04:56:26 PM »

Still trying to improve my constructed lightweight main bearing.

Housing the active pitch mechanisme in the axle is possible because of the large inside diameter.

mbouwer · « **Reply #234 on:** May 24, 2020, 10:58:48 AM »

To be able to grind the shaft ball grooves in 1 setup
I have made this mandrel as auxiliary material.

mbouwer · « **Reply #235 on:** May 26, 2020, 04:27:02 PM »

Another axle in the making. Lightweight due to 1 mm steelsheet sandwich construction.
In the hardened steel rings I grind the raceways.
But first I want to shape the hub.

SparWeb · « **Reply #236 on:** May 26, 2020, 10:31:11 PM »

Hello,
This is fascinating as usual. I do not think I understand what I'm looking at however.
Sometimes the function of a machine or component is obvious to me, other times I fail to see it.
Can you offer a description of how this axle works?

mbouwer · « **Reply #237 on:** May 27, 2020, 05:59:17 AM »

The shape of the large diameter main shaft of a large turbine inspires.
I just want to try to make a well functioning model.

Bruce S · « **Reply #238 on:** May 27, 2020, 10:07:20 AM »

You probably already know that due to vibration issues you will need to work with locking nuts along with some sort of anti-vibration filler,
Lock-tite comes to mind.
Having had a very nice 5-cyl Mercedes 300TD the Valves also had this issue. Wear and tear due to metal-on-metal will cause uneven loading.

It'll be very interesting to see this build.

Cheers
Bruce S

mbouwer · « **Reply #239 on:** May 27, 2020, 02:56:09 PM »

You're right about the locknuts and the locking fluid.
But what I make now are mostly studies that I want to disassemble again.

Bruce S · « **Reply #240 on:** May 28, 2020, 09:21:28 AM »

Quote from: mbouwer on May 27, 2020, 02:56:09 PM

You're right about the locknuts and the locking fluid.
But what I make now are mostly studies that I want to disassemble again.

Then this will be a perfect build!
I look forward to seeing the posts.

Cheers
Bruce S

SparWeb · « **Reply #241 on:** May 28, 2020, 10:31:02 PM »

I still don't see the relationship between the part you show you have made, and the one in your latest photo.
Yours has (I think) a series of free-floating wedges supporting a bearing race. If my understanding is correct, that would be a vibration/adjustment/bolt torque nightmare. I hope I am wrong.

mbouwer · « **Reply #242 on:** May 29, 2020, 04:10:07 AM »

Thanks for asking.

Reply # 237 is a professional bearing of a large turbine that I want to try to make in a much smaller version.

Reply # 234 is auxiliary material with wedges to get the shaft centric in the lathe.

Reply # 235 Clamping the shaft to grind the ball grooves.

mbouwer · « **Reply #243 on:** May 31, 2020, 04:23:21 AM »

The bearing of Reply # 233 taken apart.

The ajusting of the play is done through the bolts and nuts.
I would like to do that in a different way. For example with a saw-tooth shaped ring.

mbouwer · « **Reply #244 on:** June 08, 2020, 04:11:42 PM »

An improved version of Reply # 233
The bolts are:
- to hold together the parts of the hub
- to mount the magnet rings
- for the blade suspension

mbouwer · « **Reply #245 on:** June 10, 2020, 04:48:27 AM »

Suspension disc for the axle.

mbouwer · « **Reply #246 on:** June 10, 2020, 04:57:47 AM »

Axle and suspension.
I want to make a new version of this with a larger pitch circle for the axle mounting.

mbouwer · « **Reply #247 on:** June 13, 2020, 05:51:27 AM »

This is the axle shape, with larger suspension ring, with which I want to continue.
The ring with the front raceway can lock the hub.

mbouwer · « **Reply #248 on:** June 14, 2020, 10:40:37 AM »

Starting point is the outer rings of 2 discarded bearings with diameters of 80 and 90 mm.

mbouwer · « **Reply #249 on:** June 17, 2020, 05:07:21 AM »

After halving the outer rings I have 2 rings for the axle and 2 for the hub.

mbouwer · « **Reply #250 on:** June 19, 2020, 12:11:45 PM »

This hub I want to shape from a sandwich of 1 mm steel plate.
Grinding the raceways in the hardened rings afterwards.

mbouwer · « **Reply #251 on:** June 20, 2020, 11:10:00 AM »

Just completed further and painted the parts of the hub.

Constructing an angular contact main shaft bearing with a large inner diameter and low weight is a bit of a challenge.
My idea is that succeeding will bring many advantages.

SparWeb · « **Reply #252 on:** June 20, 2020, 10:32:00 PM »

Those bearing races are interesting - and a little confusing. Many questions come to mind. I cannot visualize how the bearing will work in the complete assembly. How will be balls be retained? How will the grease be retained?

I just re-packed the hubs on my utility trailer this morning, so the conventional arrangement of hub bearings is fresh in my mind. This isn't the only form of angular contact bearing, but it is the most common. The angular contact bearings with ball bearings that I've seen and used (aerospace parts) tend to have very thick races and wiper seals.

How will your bearing deal with distortion of the 1mm sheet?

mbouwer · « **Reply #253 on:** June 21, 2020, 10:04:22 AM »

For me it is also exciting if this will work.
Based on previous versions I arrive at this shape.
The balls are being enclosed (adjustable play) in the grease in the grooves.

The two halves that will form the hub.
The clamping points are needed for the attachment in the chuck to grind the raceways.

SparWeb · « **Reply #254 on:** June 21, 2020, 07:27:19 PM »

Sure, but did you weld the 1mm sheet to the bearing races?

mbouwer · « **Reply #255 on:** June 22, 2020, 04:50:15 AM »

The 1 mm plate is MIG ( shielding gas: mixture of CO2 and Argon ) welded all around to the hardened rings.
In addition, I made some comparable welds on another ring and tried to smash this. The welds did not break.

mbouwer · « **Reply #256 on:** June 23, 2020, 06:27:43 AM »

The axle shaping.

mbouwer · « **Reply #257 on:** June 24, 2020, 05:24:13 AM »

Shaping the axle I want to start from the suspension flange.
Added 3 ( hollow) clamping points for the chuck.

mbouwer · « **Reply #258 on:** June 25, 2020, 10:50:04 AM »

The inner sleeve, made of 1 mm sheet steel, is welded to the suspension flange.

By using an inner and outer sleeve for the main shaft ( instead of solid ) I think I can save weight.

mbouwer · « **Reply #259 on:** June 27, 2020, 05:31:25 AM »

The hardened steel ring is now included and is part of the shaft
Stiffening profile is 1 mm sheet steel.
The second hardened steel ring slides onto the mounting ring.

mbouwer · « **Reply #260 on:** July 01, 2020, 04:55:32 AM »

The raceways in the hub are grinded out.
Now I can determine the exact dimension of the axle.

mbouwer · « **Reply #261 on:** July 02, 2020, 11:52:29 AM »

Shaft and mounting ring + hardened raceway ring.

To keep it firmly in place the ring has a clamp fit and 9 bolts.

mbouwer · « **Reply #262 on:** July 14, 2020, 05:04:48 AM »

Now I can grind the raceways in the axle rings.

mbouwer · « **Reply #263 on:** July 16, 2020, 04:55:26 AM »

The hub rotates neatly around the shaft
2 raceways with 61 balls each. Weight 1762 grams.
A base for the generator and blade suspension,
and with a suitable inner diameter for active pitch control.

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Author Topic: axial generator with lamination core (Read 114367 times)